I have a similar problem with two of the file maintenance functions I ran.
 
1.  I ran SM-J-D Consolidate Inventory Transactions.  We had transactions dating back to 2003 and I consolidated up to 1/1/2006.  My problem is that after doing that, my INVTXN_B file increased by a bit more than 25%.  
 
2.  I also ran SM-J-J Purge Closed Sales Orders.  It also increased both BKARINV, and BKARINVL.
 
I've started to look through INVTXN to see whats in there, but there are only a few records dating back to before 2006 still in there.  I may run a full comparison of the old file and the new one to see exactly what's different.
 
Anybody have any ideas?  Anybody run these programs succesfully?
 
I'm running 2004.1 right now.  I plan to be running EVO in a couple weeks; will that help this problem?
 
Thanks!!
 
Julian

you need to use the Pervasive Rebuild utility, and Rebuild the INVTXN file, which will adjust the physical size due to the record consoldation.
 
don't forget to make a backup, prior to using the Rebuild utility.